Thermoplastic Coating Formulations For High-Velocity Sprayer Application and Methods For Applying Same

ABSTRACT

Tunable thermoplastic polymer powder feedstock formulations and tunable conductive thermoplastic polymer powder feedstock formulations are disclosed for delivery to a high-velocity sprayer are presently disclosed, along with tunable coatings made from the disclosed formulations, and methods for delivering such tunable thermoplastic polymer coatings to substrates.

TECHNOLOGICAL FIELD

The present disclosure relates generally to the field of coatings andsealants. More specifically the present disclosure relates to the fieldof coatings and sealants, including conductive coatings and sealants,particularly those coatings and sealants applied to a surface by thermalspraying.

BACKGROUND

In many fields, components on large structures, including those found onvehicles, including aircraft, etc., are typically coated with paints,primers, coatings, etc. that can provide a number of important functionsto a substrate surface, including, for example, protection fromcorrosion and other forms of environmental degradation, overcoat orsealant adhesion, abrasion resistance, appearance, etc. Coating andsealants are often applied to areas of assembled components orsub-assemblies that are difficult to access through traditional coatingand sealant application processes. Further, many coatings and sealantsrequire lengthy curing protocols, or require applying heat or otheradded triggering mechanism (e.g. ultraviolet radiation, etc.) to obtainan appropriate degree of curing.

Further, some coatings (e.g. paints and primers, etc.) and sealants areoften electrically insulative and can result in an impediment to thedissipation of static and other electrical charges. However, certainstructures require the need to dissipate electrical charges that buildup on a structure's interior and/or exterior surfaces, including staticelectrical charges, and charges resulting from, for example lightningstrikes, etc. The need for electrical charge dissipation is increasinglyimportant in the aircraft industry, as aircraft manufacture continues toincorporate non-metallic materials. Further, in certain aircraftassemblies, non-metallic materials, such as composites, plastics, etc.,that do not dissipate electrical charges predictably across theirsurfaces may be joined with, or otherwise contact, assemblies andsub-assemblies that comprise metallic materials that do conductelectrical charges. That is, components, assemblies and sub-assembliesthat include both composite and metallic materials may be used in themanufacture of, or otherwise incorporated into, larger structures (e.g.aircraft).

Such structures may encounter electromagnetic effects (EMEs) including,for example, and without limitation, lightning strikes. When a structureencounters an EME, the charge delivered to the structure travelsthroughout any conductive path, and can cause damage to exposeddielectric materials including, for example, composite materials. Theelectrical damage to composite materials from EMEs can be exacerbated ifthe edges of the composite material comprise exposed carbon fibers. Ifthe path of charges resulting from an EME encounters varying materialshaving varying conductivities, damage at or near the material interfacecan occur. Such interfaces include, without limitation,fasteners/substrate interfaces; and can further include joint interfaceswhere, for example, seals occur.

Carbon fiber reinforced plastic materials (CFRPs) have utility instructures including, without limitation, vehicles including, withoutlimitation, aircraft. CFRPs comprise a fiber material (e.g. carbonfibers, etc.) impregnated with a resin material (e.g. epoxy resin,acrylic resin, etc.) to make so-called prepregs. Prepregs are partiallycured layers that can be manufactured into rolls that can yield unrolledsheets for use in composite material manufacture. Prepreg material, or“prepregs” can then be “laid-up” or “stacked” into multi-layered“stacks” that can be shaped on forming mandrels or other tooling,followed by curing or partially curing the shaped material to produce acomposite material that, if desired, adopts desired and predeterminedshapes and dimensions imparted by the tool, with the composite materialhaving desired weight and strength. Alternately, prepregs may beoriented into a stack that is trimmed and cured to form a solid stackfor use as a composite material structure or other type of compositecomponent.

In aircraft manufacture, CFRP parts are often joined to metallic parts.Problems can occur with respect to predictably dissipating electricalcharges when materials, such as CFRPs and various metals (e.g. aluminum,titanium, etc.) that have differing conductivities are joined, fastened,or are otherwise in close proximity to one another.

Coatings, especially coatings used in aircraft manufacture, also must berobust enough to possess a plurality of characteristics, but may notadequately provide all of the required functions to an equivalent oracceptable degree. For example, conductive coatings for dissipatingelectrical charges across metallic and non-metallic coatings alike havebeen tried with varying success. However, the known conductive coatingsmust be loaded with conductive particles to such an extent (sometimes asmuch as 50-70 weight percent), that other required coatingcharacteristics suffer.

In addition, surface coatings that may be designed to alleviateelectrical imbalances across various metallic and/or non-metallicsurfaces must often, at least in part, address additional concerns andfunctions including appearance, adhesion, abrasion resistance,environmental degradation, etc.

Further, inherent coating characteristics (viscosity, etc.,) may make itdifficult to apply such coatings to restrictive locations and surfacesusing efficient application techniques. For example, an otherwisedesirable coating may be too viscous to apply to a surface usingsprayers, when an application mode such as spraying could otherwiseoffer improvements to coating processing in terms of, efficiency, costsavings, etc.

In addition, specialized coatings having a useful range of varyingproperties may be expensive to prepare, maintain, store, or deploy.Otherwise useful coatings may further have long curing times, forexample taking days to cure with or without the presence of elevatedcuring temperatures or the use of additional triggering processes. Suchextended or complex curing regimens further add to the manufacturingtime required, as well as increasing cost. In addition, specializedcoatings may lack an adequate shelf life or pot life to be useful forvery long on-site. It may further be economically impractical for aparticular manufacturing facility (in terms of equipment or spacerequirements) to store and/or inventory coatings that require, forexample, maintenance at particular temperatures.

SUMMARY

Present aspects disclose a thermoplastic polymer powder feedstock fordelivery to a high-velocity sprayer for the purpose of depositing athermoplastic polymer coating to a substrate surface or a portion of asubstrate. The use of a thermoplastic polymer powder feedstock materialor mixture of thermoplastic polymer powder feedstocks directed to ahigh-velocity sprayer (e.g. thermal or cold sprayer) allows a user totailor or “tune” the characteristics of the resulting thermoplasticcoating that is deposited onto a substrate, or portion of a substrate;including substrates that are difficult to access. Since the depositedcoatings are made from thermoplastic materials, the thermoplasticcoatings exhibit enhanced adhesion, do not require a curing regimen,display significantly reduced or toxicity, and can be deposited from ahigh-velocity sprayer that can be a thermal sprayer or a cold sprayer.

Further, according to an aspect of the disclosure, when a depositedmaterial or material layer deposited onto a substrate is required tohave a particular conductivity or resistivity different from the basesubstrate material or substrate materials (e.g., at a joint orinterface), conductive powders can be added to the thermoplastic polymerpowder feedstock. In an alternative the conductive powder is separatelyand substantially concurrently delivered to a sprayer with thethermoplastic polymer powder feedstock (e.g., the conductive powderdelivered separately to the sprayer) such that a predetermined amount ofconductive powder is incorporated into, or supplied to a sprayerconcurrently with, the thermoplastic polymer powder feedstock. In thisway, the thermoplastic polymer coating delivered to a substrate surfaceby the sprayer will have desired preselected conductivity andresistivity characteristics.

According to an aspect, a powdered feedstock formulation for ahigh-velocity sprayer is disclosed including at least one thermoplasticpolymer powder. In another aspect, the thermoplastic polymer powderincludes at least one of nylon, polyetheretherketone (“PEEK”),polyetherketoneketone (“PEKK”), polyamide, polyphenylsulfide,polyphenylsulfone, polysulfone, polyetheramide, and copolymers includingHytrel® TPC-ET (DuPont®), thermoplastic elastomers, and thermoplasticfluoroelastomers including DAI-EL® T-530 (Daikin®).

In another aspect, a powdered feedstock formulation includes at leastone thermoplastic polymer powder combined with a conductive powder toform a conductive thermoplastic polymer powder feedstock, with theconductive powder present in the thermoplastic polymer powder feedstockin an amount ranging from about 1% to about 9% by volume of thefeedstock formulation. In another aspect, the conductive powder includesat least one of titanium, nickel alloy, copper, carbon black, graphenepowder, or carbon nanotubes.

In another aspect, the thermoplastic polymer powder and the conductivepowder are mixed into a single conductive feedstock. In a furtheraspect, the thermoplastic polymer powder and the conductive powder arenot mixed into a feedstock before separately supplying the twocomponents to a sprayer. According to an aspect, the thermoplasticpolymer powder and the conductive powder are provided via separatefeedstock supply lines to the sprayer, substantially concurrently.

In another aspect, a thermoplastic polymer powder feedstock includes twoor more different thermoplastic polymer materials.

In another aspect, a system is disclosed that includes a thermoplasticpolymer powder feedstock including at least one of nylon,polyetheretherketone, polyetherketoneketone, polyamide,polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide.The system further includes a high-velocity sprayer in communicationwith the thermoplastic polymer powder feedstock.

In another aspect, the thermoplastic polymer powder feedstock includesat least two of nylon, polyetheretherketone, polyetherketoneketone,polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, andpolyetheramide.

In another aspect, the thermoplastic polymer powder feedstock includesat least one conductive powder and at least one of nylon,polyetheretherketone, polyetherketoneketone, polyamide,polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide.

In another aspect, the thermoplastic polymer powder feedstock furtherincludes a conductive powder to form a conductive thermoplastic polymerpowder feedstock mixture, with the conductive powder including at leastone of titanium, nickel alloy, copper, carbon black, graphene powder, orcarbon nanotubes. In another aspect, the conductive powder is present inthe conductive thermoplastic polymer powder feedstock mixture in anamount ranging from about 1% to about 9% by volume of the conductivethermoplastic polymer powder feedstock mixture.

In another aspect, systems are disclosed where different thermoplasticpolymer powder feedstocks are provided with or without a conductivepowder and the conductive various powders are not mixed beforeintroducing each of the powders to a sprayer. In such aspect, theseparate components (e.g., one or more different thermoplastic polymerpowder feedstocks and a conductive powder) are directed separately froma discrete supply of the various powder feedstocks to the sprayer viaseparate feedlines. In a further aspect, the separate feeds of thedifferent powder feedstocks are directed and/or delivered substantiallyconcurrently to the sprayer via separate feedlines, or are directed tothe sprayer according to a programmed delivery sequence from separatefeedstocks through a single feedline.

In yet another aspect, the high-velocity sprayer is in communicationwith a robot or a robotic arm that is in turn in communication with acontroller for directing the motion of the sprayer. One or more furthercontrollers can be in communication with the sprayer to control theamounts of feedstock powders delivered to the sprayer, as well ascontrolling the amount of thermoplastic polymer powder feedstockmaterial and the amount of the conductive powder feedstock delivered toa substrate surface as a coating on the substrate surface.

Further aspects are directed to methods for delivering a thermoplasticcoating to a substrate surface, with the method including directing anamount of at least one thermoplastic polymer powder feedstock to ahigh-velocity sprayer to form a thermoplastic spray formulation, withthe formulation including at least one of nylon, polyetheretherketone,polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone,polysulfone, and polyetheramide. The thermoplastic polymer sprayformulation is then directed from the high-velocity sprayer to asubstrate surface, followed by forming a thermoplastic polymer coatingon the substrate surface. The high-velocity sprayer can be a thermalsprayer or a cold sprayer.

In another aspect, a two or more different thermoplastic polymer powderfeedstocks are directed to the high-velocity sprayer and the differentthermoplastic polymer powder feedstocks are either first mixed togetherto form a thermoplastic polymer powder feedstock mixture that is thendirected to the sprayer via a single feed line, or the differentthermoplastic polymer powder feedstocks are directed separately to thehigh-velocity sprayer via separate feed lines. According to anotheraspect, the separately directed thermoplastic polymer powder feedstocksare directed to the high-velocity sprayer substantially concurrently, orare directed to the sprayer via one or more feedlines according to aprogrammed delivery sequence. In yet another aspect, the high-velocitysprayer is in communication with a robot or a robotic arm that is inturn in communication with a controller for directing the motion of thesprayer. One or more further controllers can be in communication withthe sprayer to control the amounts of one or more thermoplastic polymerpowder feedstock materials delivered to the sprayer as well ascontrolling the amount of thermoplastic polymer coating delivered to asubstrate surface.

In further aspects, methods include combining the at least onethermoplastic polymer powder feedstock with a conductive powderfeedstock to form a conductive thermoplastic polymer powder mixture as afeedstock, with the conductive powder present in the conductivethermoplastic polymer powder feedstock mixture in an amount ranging fromabout 1% to about 9% by volume of the feedstock mixture formulation. Inanother aspect, the conductive powder feedstock includes at least one oftitanium, nickel alloy, copper, carbon black, graphene powder or carbonnanotubes. As described above, instead of mixing different powderedfeedstock components, the differing feedstock powders can be deliveredto the high velocity sprayer via separate feedlines, and are thereforecombined at the sprayer. According to another aspect, the separatelydirected thermoplastic polymer powder feedstocks (alone, or incombination with the conductive powder feedstock(s)) are directed to thehigh-velocity sprayer substantially concurrently, or are directed to thesprayer via one or more feedlines according to a programmed deliverysequence.

According to further aspects, when a thermoplastic polymer powderfeedstock provided as a spray formulation includes a conductive powderfeedstock component, the resulting conductive thermoplastic coatingdelivered from the sprayer to a substrate surface has a resistivityranging from about 1×10e⁵ to about 1×10e¹¹ ohm-meter (ohm-m), andpreferably from about 1×10e⁵ to about 1×10e⁸ ohm-m.

Aspects of the present disclosure further contemplate, withoutlimitation, objects, components, sub-assemblies, assemblies havingsubstrate surfaces that include the thermoplastic coating and/or theconductive thermoplastic coating delivered to a substrate surfaceaccording to the methods presented. with the objects including, forexample, and without limitation, a manned aircraft, an unmannedaircraft, a manned spacecraft, an unmanned spacecraft, a mannedrotorcraft, an unmanned rotorcraft, a satellite, a rocket, a mannedterrestrial vehicle, an unmanned terrestrial vehicle, a manned orunmanned hovercraft, a manned surface water borne vehicle, an unmannedsurface water borne vehicle, a manned sub-surface water borne vehicle,an unmanned sub-surface water borne vehicle, and combinations thereof.

The features, functions and advantages that have been discussed can beachieved independently in various aspects or may be combined in yetother aspects, further details of which can be seen with reference tothe following description and the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Having thus described variations of the disclosure in general terms,reference will now be made to the accompanying drawings, which are notnecessarily drawn to scale, and wherein:

FIG. 1 is an illustration of an aspect of the present disclosure showinga thermoplastic polymer powder feedstock and a system including thethermoplastic polymer powder feedstock and a high-velocity sprayer fordepositing a thermoplastic polymer coating onto a substrate surface;

FIG. 2A is an illustration of an aspect of the present disclosureshowing the mixing of more than one thermoplastic polymer powderfeedstocks to form a thermoplastic powder feedstock mixture for use as aspray formulation, and a system including the thermoplastic powderfeedstock mixture and a high-velocity sprayer for depositing a tunablethermoplastic polymer coating onto a substrate surface;

FIG. 2B is an illustration of an aspect of the present disclosureshowing a plurality of thermoplastic powder feedstocks delivered viaseparate feedlines to the sprayer shown in FIG. 2A, and a system fordepositing a tunable thermoplastic polymer coating onto a substratesurface;

FIG. 3A is an illustration of an aspect of the present disclosureshowing at least one thermoplastic polymer powder feedstock mixed withat least one conductive powder feedstock to form a conductivethermoplastic powder feedstock mixture, and a system including theconductive thermoplastic polymer powder feedstock mixture and ahigh-velocity sprayer for depositing a conductive thermoplastic polymercoating onto a substrate surface;

FIG. 3B is an illustration of an aspect of the present disclosureshowing at least one thermoplastic polymer powder feedstock and aconductive powder feedstock shown in FIG. 3A, and a system including ahigh-velocity sprayer for depositing a conductive thermoplastic polymercoating onto a substrate surface, with more than one thermoplasticpolymer powder feedstock and the one or more conductive powder feedstockdelivered or directed to the sprayer via separate feed lines;

FIG. 4A is an illustration of an aspect of the present disclosureshowing more than one thermoplastic polymer powder feedstocks mixed witha conductive powder feedstock to form a conductive thermoplastic powderfeedstock mixture, and a system including the conductive thermoplasticpolymer powder feedstock mixture and a high-velocity sprayer fordepositing a conductive thermoplastic polymer coating onto a substratesurface;

FIG. 4B is an illustration of an aspect of the present disclosureshowing two different thermoplastic polymer powder feedstocks and aconductive powder feedstock shown in FIG. 4A, and a system including thetwo different thermoplastic polymer powder feedstocks, the conductivepowder feedstock and a high-velocity sprayer for depositing a conductivethermoplastic polymer coating onto a substrate surface, with the twothermoplastic polymer powder feedstocks and the conductive powderfeedstock delivered or directed to the sprayer via separate feed lines;

FIG. 5 is an illustration of an aircraft;

FIG. 6 is a flowchart outing a method according to aspects of thepresent disclosure;

FIG. 7 is a flowchart outing a method according to aspects of thepresent disclosure;

and

FIG. 8 is a flowchart outing a method according to aspects of thepresent disclosure.

DETAILED DESCRIPTION

Aspects of the present disclosure are directed to powdered thermoplasticformulations that can be tunable, or otherwise have theircharacteristics changed in real time during deposition and that caninclude conductive materials and that can also be conductively tunable.The powdered thermoplastic polymer feedstocks can include at least oneconductive powdered material to form a conductive thermoplastic powderfeedstock mixture that can be deposited onto a substrate surface via ahigh-velocity sprayer to form a tunable conductive thermoplastic coatingon a substrate surface, with the conductive thermoplastic coating havingpredetermined characteristics.

Aspects of disclosed thermoplastic polymer powder powdered conductivecoating formulations can be tuned or tailored, including in real time,to provide a wide range of required coating characteristics, while alsoproviding robust protective coating qualities to the substrates beingcoated with the presently disclosed thermoplastic coatings.

According to further aspects, powdered conductive thermoplastic polymercoating formulations (that contain a conductive powder) can be tuned ortailored, including in real time, and provide a wide range of requiredcharacteristics for electrically conductive thermoplastic coatingsoffering a particular, and wide-ranging amount of resistivity orconductivity, while also providing robust protective qualities to thesubstrates being coated with the presently disclosed conductivethermoplastic coatings.

Additionally, aspects of the present disclosure are directed tothermoplastic polymer powder coating formulations that can be tailoredas precursor feedstock mixtures, or that can be delivered substantiallyconcurrently or in predetermined sequence to a sprayer (e.g., apredetermined programmed sequence) from separate feedstock sources orsupplies to a high velocity sprayer. The sprayer then delivers thethermoplastic polymer powder coating formulations to form athermoplastic coating, using high-velocity spraying techniques, tometallic and/or non-metallic substrates and components, with thethermoplastic coatings having predetermined characteristics that can betuned in real time (e.g., in real time during application to a substratesurface, etc.). When a conductive powdered feedstock material is presentin the thermoplastic polymer powder feedstock, various characteristicsof the resulting applied conductive thermoplastic coatings can bepredictably tailored, even in substantially real-time, by changing theproportions of powdered feedstock constituents (e.g., the proportion(s)of the at least one thermoplastic polymer powder feedstock and theconductive powder feedstock) that are provided to the sprayer.

Without being limiting, the average particle size of the thermoplasticpolymer powder feedstock(s) used according to aspects of the presentdisclosure range from about 20 μm to about 300 μm. In addition, withoutbeing limiting, the average particle size of the conductive powderfeedstock(s) used according to aspects of the present disclosure rangefrom about 5 μm to about 80 μm. The high-velocity sprayers used inconnection with aspects of the present disclosure include sprayers ableto disperse a feedstock at velocities ranging from about 20 m/s to about1200 m/s. Such sprayers include thermal (e.g., flame sprayers, etc.) andcold sprayers.

According to one aspect, the thermoplastic polymer powder comprises atleast one of a nylon, polyetheretherketone (equivalently referred to asPEEK), polyetherketoneketone (equivalently referred to as PEKK),polyamide, polyphenylsulfide, polyphenylsulfone, polysulfone, andpolyetheramide.

In further aspects, the thermoplastic polymer powder feedstock comprisesat least one of a thermoplastic polyester elastomer powder or athermoplastic fluoroelastomer powder. Contemplated thermoplasticelastomer powders include those that can be obtained as PEEK, PEKK,Hytrel® 5526 (DuPont); Dai-El™, (Daikin®); Hipex®, (Kraiburg), etc. Thethermoplastic polymer powder feedstocks preferably have an averageparticle size ranging from about 20 μm to about 300 μm.

Polyether ether ketone (PEEK) is an organic thermoplastic in thepolyaryletherketone (PAEK) family, with PEEK having the general formula:

PEEK has a coefficient of thermal expansion value (depending upon grade)ranging from of about 20 to about 80 ppm/° F. (i.e. about 2 to about8×10⁻⁵ in./in/° F.), a Young's modulus value of about 3.6 GPa and atensile strength ranging from about 90 MPa to about 100 MPa. PEEK ishighly resistant to thermal degradation as well as attack by bothorganic and aqueous environments (e.g. environments including, withoutlimitation, those environments coming into contact with fuels and fuelsystems, etc.), and has a high resistance to biodegradation.

According to another, and as also presented in the Examples below, retpolymer powder. Polyetherketoneketone (PEKK) is a semi-crystallinethermoplastic in the PAEK family, with PEKK having the general formula:

PEKK has a coefficient of thermal expansion value (depending upon grade)of about 10 to about 20 ppm/° F. (i.e. about 1 to about 2×10⁻⁵ in./in/°F.), a Young's modulus value of about 4.5 GPa and a tensile strength ofabout 102 MPa. PEKK is also highly resistant to thermal degradation aswell as attack by both organic and aqueous environments (e.g.environments including, without limitation, those environments cominginto contact with fuels and fuel systems, etc.), and has a highresistance to biodegradation.

The density of the contemplated thermoplastic polymer coating depositedonto a substrate surface can be of any desired thickness, but isparticularly deposited at a thickness ranging from about 25 μm to about5 mm, with the contemplated thermoplastic coatings having a materialdensity ranging from about 1.0 g/cc to about 1.8 g/cc. Being able todeposit a thermoplastic coating having such tailorable and predetermineddensities and deposited to such desired thicknesses at reduced densitiesrealizes substantial weight reduction compared with material coatingspresently used in, for example, aircraft production where overall weightimpacts vehicle range, fuel consumption, available cargo capacity,manufacturing time, etc., all of which can impact total production cost.

If desired, according to further contemplated aspects, the thermoplasticcoatings (and when conductive components are present to form conductivethermoplastic coatings, such resulting conductive thermoplasticcoatings) can be tailored or “tuned”, for example, in real time duringthe coating deposition process, such that the deposited coatings possessvarious desired and predetermined characteristics, e.g., physical,chemical, thermal, etc. Such aforementioned tailorable characteristicsare in addition to the desired and tailorable conductivity orresistivity values achievable with the presently disclosed conductivethermoplastic coatings. This can be achieved by providing differingpowdered thermoplastic polymer feedstock(s), differing amounts (e.g.,differing comparative ratios, etc.) of differing powdered thermoplasticpolymer feedstock(s), additional numbers of differing powderedthermoplastic polymer feedstock(s), or by providing additives to thepowdered thermoplastic polymer feedstock(s).

According to other aspects, contemplated conductive powder feedstockmaterials include, without limitation, various metallic powdersincluding titanium, nickel alloy, copper, carbon black, graphene powder,or carbon nanotubes. The contemplated conductive powder feedstockmaterials preferably have an average particle size ranging from about 5μm to about 80 μm.

The powdered thermoplastic polymer feedstock formulations disclosed,according to aspects of the present disclosure, when combined orotherwise mixed with one or more conductive powder feedstock(s) producea resulting conductive thermoplastic polymer feedstock mixture thatyields a conductive thermoplastic polymer coating on a substratesurface, with the resulting conductive coating having a desired andpredetermined resistivity ranging from about 1×10e⁵ to about 1×10e¹¹ohm-meter (ohm-m), and preferably from about 1×10e⁵ to about 1×10e⁸ohm-m.

To provide a conductive thermoplastic coating on a substrate surfacehaving a resistivity ranging from about 1×10e⁵ to about 1×10e¹¹ohm-meter (ohm-m), and preferably from about 1×10e⁵ to about 1×10e⁸ohm-m, the conductive thermoplastic polymer powder feedstock(s) have arelative percentage by volume of the conductive component (e.g. theconductive powder) ranging from about 1% to about 9% by volume of thetotal volume of conductive thermoplastic polymer powder provided to thesprayer.

It is further understood that the thermoplastic polymer powder (e.g.,provided as a feedstock to the sprayer) can be a mixture that is formedprior to the introduction of the multi-component feedstock to thesprayer. In one aspect, when the powdered feedstock comprises more thanone type of powder component (e.g. more than one thermoplastic polymerpowder feedstock; one thermoplastic polymer powder feedstock and atleast one type of conductive powder feedstock; more than onethermoplastic polymer powder feedstock and at least one type ofconductive powder feedstock, etc.), the multiple component powderfeedstock materials can be mixed together to form a thermoplastic (orconductive thermoplastic) polymer powder mixture, or “feedstockmixture”. The feedstock mixture is then introduced as the feedstock tothe sprayer. For the purpose of the present disclosure, the term“feedstock” refers to a precursor material that is supplied from asupply of a material to a mixture, or is supplied directly to a sprayervia a feed line from a supply of a material.

In an alternate aspect, when the powdered feedstock comprises more thanone type of powder component (e.g., more than one thermoplastic polymerpowder feedstock; one thermoplastic polymer powder feedstock and atleast one conductive powder feedstock; more than one thermoplasticpolymer powder feedstock and at least one conductive powder feedstock,etc.), the multiple powdered feedstock components can be directed viaseparate feed lines to the sprayer, such that no multiple componentpowdered feedstock mixture is pre-formed as a single feedstock that isthen provided to the sprayer. According to this aspect, on or morecontrollers can be used to monitor and control the rate at which asingle powdered feedstock is released from a supply and directed to thesprayer. In this way, the individual flow rate of a particular powderedfeedstock component is controlled, monitored and maintained to insurethat a particular ratio of feedstock components that arrive at (e.g.,are delivered to) the sprayer is achieved and, if desired, maintainedfor the duration of the material (e.g. coating) spray deposition onto asubstrate surface. For example, in this aspect, to produce a conductivethermoplastic coating having a resistivity ranging from about 1×10e⁵ to10e⁸ ohm/m, the presence of an amount of conductive powder feedstockdelivered to the sprayer ranges from about 1% to about 9% by volume ofthe combined powdered material feedstock delivered to the sprayer (e.g.,the combined powdered material volume equaling the volume ofthermoplastic polymer powder feedstock combined with the conductivepowder feedstock volume, and, for example, controlled, monitored andmaintained by regulating the comparative flow rates of the individualcomponent feedstocks fed via one or more feed lines to the sprayer,etc.).

According to present aspects, a formed conductive thermoplastic polymerpowder feedstock mixture becomes the thermal sprayer feedstock materialthat is converted by the thermal sprayer into a conductive coating orconductive sealant that is desirably applied (via the thermal sprayer)to a metal, non-metal, or metal/non-metal interface at, for example, afastener, or a joint, or to a component edge as an edge seal. Thecomparative amount of conductive powder that is selected and added tothe thermoplastic powder to form the conductive thermoplastic powdermixture, is selected to achieve a particular conductive effect in theeventual conductive thermoplastic coating and/or conductivethermoplastic sealant that is deposited onto a substrate in the form ofa conductive coating or conductive sealant. That is, by tailoring theamount of conductive powder added to form the form the thermoplasticpowder mixture used as the thermal sprayer feedstock material, theresulting material exiting the thermal sprayer and deposited onto asubstrate surface will become a coating or sealant having a particularlypreselected resistivity on the substrate surface.

The tailorable conductive thermoplastic coatings that are obtainedaccording to aspects of the present disclosure provide conductiveflexibility with respect to dissipating static charges that build upwith and along a particular material, or are caused by significantelectrical events including, for example, lightning strikes. Inaddition, the conductive thermoplastic coatings disclosed herein havesignificant advantages commensurate with thermoplastic coatings in termsof ease of handling, ease of application, retention and adhesioncharacteristics, safety due to lower toxicity (e.g., as compared withpolysulfides and chromates, etc.), etc.

Still further, since the presently disclosed conductive coatings arethermoplastic in nature, the conductive thermoplastic coatings orsealants do not require a separate curing step after application. Inother words, the thermoplastic coatings/sealants will “set” upon coolingand require no subsequent curing protocol or regimen to “set up”. Thedisclosed thermoplastic polymer coatings and conductive thermoplasticpolymer coatings can be fabricated to further comprise a particularcolor to, for example, facilitate inspection with respect to bothinitial application quality as well as repair and maintenanceinspections that will be conducted at various quality control andservicing intervals. Still further, if repair or replacement of athermoplastic polymer coated part or surface (or a conductivethermoplastic polymer coated part or surface) is required, such coatedparts or the coatings on such coated parts can be more easily removedusing various solvent or mechanical removal as compared to, for example,epoxy- or acrylamide-based coatings and/or sealants that require curingregimens.

With respect to adhesion, the conductive coatings/sealants of thepresent disclosure have adhesion values ranging from about 5 lbs/in toabout 50 lbs/in wide area on both metals and non-metals when performingadhesion testing set forth in ASTM D6862-11(2016) Standard Test Methodfor 90° Peel Resistance.

In this way, the thermoplastic coating and sealant systems disclosedherein combine the benefits of thermoplastic material characteristicswith high-velocity spray techniques and systems (e.g., thermal flamespraying and cold spraying), and the deposited thermoplastic coating andsealant characteristics are further tailorable to a desired end use ascoatings and/or sealants on a substrate surface. When a conductivepowder feedstock component is added to the thermoplastic powderfeedstock, the conductive coatings deposited to a substrate surface haveelectrical characteristics (e.g., conductivity, resistivity, etc.) thatcan also be tailored as required for their intended use as conductivecoatings, particularly as coatings and/or sealants on homogeneous orhybrid surfaces comprising metallic and/or non-metallic components.

According to a further aspect, the presently known thermal and coldspray equipment and systems can be retrofitted to deposit coatings madefrom the presently disclosed thermoplastic formulations that can alsoinclude conductive materials to form conductive thermoplastic coatings.Particularly preferred thermal sprayers include flame sprayers.

Thermal spraying techniques are coating processes where melted or heatedmaterials are sprayed onto (e.g., deposited onto) a surface. Feedstockmaterial is supplied to the sprayer as a coating precursor. Thefeedstock is heated by electrical (e.g., plasma or arc) or chemicalmeans (e.g., combustion flame). Thermal spraying can achieve coatingshaving a coating thickness ranging from about 20 μm to about 5.0 mm overa large area and at a high deposition rate as compared to other knowncoating processes, with the presently contemplated deposition rateranging, for example, from about 20 μm on 1 ft² in 10 seconds, orgreater, etc., or coatings deposited at a rate ranging from about 1 toabout 50 grams/second (g/s), etc.

Flame spray coating refers to a type of thermal spraying where melted orheated feedstock materials are sprayed onto a substrate surface. Thefeedstock (e.g., the coating precursor material) is heated by electrical(e.g., plasma or arc) or chemical means (e.g., combustion flame). Duringcoating processes the substrate preferably undergoes no distortion, asthe substrate temperature remains below about 250° F. during the sprayoperation. When the substrate is metallic, the substrate is notmetallurgically altered. Coating thickness ranging from about 2 μm to5.0 mm can be achieved, with deposition (e.g., coating application)rates for such thicknesses ranging from at least about 20 μm on 1 ft² in10 seconds, or greater, etc., or from about 1 to about 50 g/s.

Without limitation, thermal (e.g., flame, etc.) sprayers usefulaccording to present aspects include, for example, TAFA Models 5220HP/HVOF®, 8200 HP/HVOF®, 825 JPid HP/HVOF® (ID), 7780 (UPCC), JP-8000HP/HVOF®, JP-5000® HP/HVOF® (Praxair, Inc., Danbury, Conn.); Powderjet86, Powderjet® 85 (Metallizing Equipment Co. Pvt. LTD. (Jodhpur, India)Plasma Technology Inc., Torrence, Calif.): and systems available fromPlasma Technology Inc. (Torrence Calif.), etc. Universal Flame SpraySystem PG-550 (Alamo Supply Co., Ltd., (Houston, Tex.), etc. Variouscontrollers can be used in conjuction with the TAFA systems describedincluding, for example, TAFA Model 7700GF HVOF System (Praxair, Inc.,Danbury, Conn.).

In contrast with the flame sprayer systems mentioned above, in “coldspray” systems powder particles (e.g., feedstock particles) typicallyhaving an average particle size ranging from about 10 μm to about 40 μm,and are accelerated to very high velocities (200 to 1200 m/s) by asupersonic compressed gas jet at temperatures below their melting point.Upon impact with the substrate, the particles experience extreme andrapid plastic deformation that disrupts the thin surface oxide filmsthat are present on all metals and alloys. This allows intimateconformal contact between the exposed substrate surfaces under highlocal pressure, permitting bonding to occur with the layers of depositedmaterial. The layers of deposited material can be built up rapidly, withvery high deposition efficiency (e.g., above 90% in some cases). Usingcold spray systems, materials can be deposited without high thermalloads, producing coatings with low porosity and oxygen content. Withoutlimitation, cold sprayers useful according to present aspects include,for example, Impact Spray System 5/8; Impact Spray System 5/11 (ImpactInnovations Waldkraiburg, Germany), etc.

Cold spray processes refer to the thermal spray processes andcollectively refers to processes known as cold gas dynamic spraying,kinetic spraying, high velocity particle consolidation (HPVC), highvelocity powder deposition, supersonic particle/powder deposition (SPD),and the like. In cold spraying, a high velocity gas jet, for example, adeLaval converging/diverging nozzle can be used to accelerate powderparticles generally having an average particle size ranging from about 1μm to about 50 μm. The particles are accelerated by the gas jet at atemperature that is below the melting point of the feedstock materialparticles. The particles are then sprayed onto a substrate that can belocated about 25 mm from the nozzle. The particles impact the substrateand form a coating. Without being bound by a particular theory, it isbelieved that the kinetic energy of the particles, rather than anelevated temperature causes the particles to plastically deform onimpact with the substrate surface to form “splats” that bond together toproduce the coating. The coatings formed from the cold sprayed particlesare formed in the solid state, and not via the melting followed bysolidification as occurs in thermal spray processes (e.g., flamespraying, etc.) using elevated temperature. Such a cold spray processavoids deleterious effects that can be caused by high temperaturedeposition, including, for example, high-temperature oxidation,evaporation, melting, crystallization, residual stress, gas release,etc. As a result, according to present aspects, cold spraying can beadvantageously used for temperature sensitive (e.g., heat sensitive)substrates. The resulting coatings according to present aspects, possesscharacteristics including high strength, low porosity and minimalresidual stress.

As mentioned above, characteristics of the thermoplastic coatingscontemplated according to present aspects can be altered in apredetermined fashion by providing a predetermined combination ofmaterials to form a tailored thermoplastic polymer powder feedstockmaterial, and by further incorporating additives, including, withoutlimitation, additives such as pigments, dyes, or coloring agents, etc.Such coloring agents can facilitate the inspection of the condition ofcoatings during, for example, inspections, etc.

As mentioned previously, the sprayers used in the systems and methodsdisclosed herein can be operated manually, but can also be automated byincorporating or otherwise attaching the sprayer to a robot, or roboticarm that includes or is in communication with sensors, controllers,software and hardware, etc. for the purpose of controlling the operationand movement of the sprayer and the operation of the sprayer during, forexample a material deposition (e.g., coating, etc.) cycle. The robot andequipment associated with the robot and sprayer can be operated andpowered directly, and further can be operated remotely in response to,for example, wireless signals, etc.

Where coating characteristics have included robustness in terms ofadhesion and/or resistance to environmental factors such as thoseencountered, for example, in vehicle fuel tanks, etc., coating materialshave been classified with various toxicities, making their handling andapplication hazardous to personnel. In addition, various applicationsites have been difficult to access. In addition, maintaining and/orreplacing the coatings presently in use has resulted in significantrepair and replacement time, as the removal of cured coatings. Thecoatings made possible according to aspects of the present disclosure,being thermoplastic materials, have significantly reduced toxicityduring application, and can be more easily removed and replaced (e.g.,at scheduled routine inspection and/or replacement).

In addition, the presently disclosed coatings made from the disclosedthermoplastic polymer powder formulations maintain adhesioncharacteristics over a required service period that is at leastequivalent to or exceeds that, which is achievable using the previouslyavailable coatings and sealants (e.g., epoxy and acrylamide basedoptions, etc.). The adhesion of the thermoplastic polymer coating madefrom the disclosed thermoplastic polymer powder formulations have anadhesion ranging from about 5 to about 50 lbs./in² wide area whenperforming adhesion testing set forth in ASTM D6862-11(2016) StandardTest Method for 90° Peel Resistance.

When a conductive film or coating is desired, the contemplatedthermoplastic polymer coatings, sealants, films, etc. can be tailored toachieve a desired surface resistivity, for example, ranging from about1×10e⁵ to about 1×10e¹¹ ohm-meter (ohm-m), and preferably from about1×10e⁵ to about 1×10e⁸ ohm-m, when the conductive component compositionof the thermoplastic polymer powder feedstock ranges from about 1% toabout 9% by volume of the conductive thermoplastic polymer powderfeedstock. The desired characteristics of the coating produced,including, for example, the desired resistivity, setting time,thickness, etc., determines the concentration of the conductive powderfeedstock component that is incorporated into the thermoplastic polymerpowder feedstock, or that is supplied to the sprayer substantiallyconcurrently with the thermoplastic polymer powder feedstock (e.g., inthe situation where feedstocks are supplied to the sprayer separatelyand a feedstock mixture is not prepred and then delivered to thesprayer.

Coatings and sealants typically applied to spatially restrictive andother difficult-to-access areas in various assemblies and sub-assembliesfound, for example, in vehicles including aircraft have requiredcoatings and sealants (e.g., epoxies and acrylamides, etc.) that requiresignificant curing times in excess of many days. Components for use insuch assemblies and sub-assemblies comprising the presently disclosedcoatings find particular utility in the manufacture of vehicles,including aircraft, as well as structural components used in themanufacture of fuel tanks on such vehicles.

Further, long curing times delay manufacturing and increasemanufacturing cost. In contrast to epoxy-based and other materialsrequiring curing time of several days or longer, the presently disclosedthermoplastic polymer coatings and sealants applied according to thepresently disclosed methods do not require curing, and only require thetime necessary for the thermoplastic material to cool and “set” (e.g.thermoplastic material “set” times understood to range from about lessthan a few mins. to about several mins., or the amount of time athermoplastic material takes to cool from an applied temperature toabout room (ambient) temperature, assuming coating thicknesses rangingfrom about 2.5 mm to about 5.0 mm). According to present aspects, such“set” times for the deposited thermoplastic polymer coatings andsealants disclosed herein (including the deposited conductivethermoplastic polymer coatings and sealants) are in strong contrast tothe curing times of several hours or even several days that are requiredto cure sealants and coatings previously used for the purposes intendedherein on the substrates and substrate surfaces intended and disclosedherein.

While many of the characteristics of thermoplastic polymers may havebeen desirable for use in coatings and sealants in hard to accesslocations in assemblies and sub-assemblies, use of such thermoplasticpolymeric coatings had been particularly hampered where the coatings orsealants required conductivity (or needed to have certainresistivities), or where it had not been previously possible to deposita thermoplastic coating having variable or tailored characteristics.According to aspects of the present disclosure, the fabrication and useof electrically conductive coatings and sealants that have multiplephysical and chemical characteristics tailored that are made frompresently disclosed thermoplastic polymer powder formulations, andapplied according to presently disclosed methods has now been achieved.

FIG. 1 shows a block diagram outlining an aspect showing a thermoplasticpolymer powder feedstock and a system 10 including directing thethermoplastic polymer powder feedstock to a high-velocity sprayer fordepositing a thermoplastic polymer coating onto a substrate surface. Asshown in FIG. 1, a thermoplastic polymer powder feedstock 12 is directedfrom a thermoplastic polymer powder feedstock supply via a feedline 11in communication with the thermoplastic polymer powder feedstock 12 andalso in communication with a high-velocity sprayer 14. Predeterminedamounts of the thermoplastic polymer powder feedstock 12 can be directedby any desirable means that will direct the thermoplastic polymer powderfeedstock 12 to the high-velocity sprayer 14, including automated meansregulated by a controller (not shown) and subject to, for example,software and hardware known to control, for example, feedstock flowrates, etc. The high-velocity sprayer can be a thermal sprayer or a coldsprayer. As shown in FIG. 1, the thermoplastic polymer powder feedstock12 is converted by the high-velocity sprayer 14 into a thermoplasticpolymer coating 16 a onto substrate 16. While the high-velocity sprayer14 can be operated manually, FIG. 1 shows an optional robotic arm 13(equivalently referred to herein as a “robot”) that can be incommunication with a controller 15. Controller 15 can further optionallybe in communication with remote or integrated software or hardware, asdesired, to control robotic arm movement as well as control flow ratesand amounts of material deposited as a thermoplastic coating 16 a onto asubstrate 16. Optionally, additional controllers (not shown) can beintegrated into system 10 to control one or more aspects of system 10.

FIG. 2A shows a block diagram outlining an aspect showing athermoplastic polymer powder feedstock mixture and system 20 includingmixing multiple thermoplastic polymer powder feedstocks to form athermoplastic powder mixture, and then directing an amount of thethermoplastic powder mixture to a high-velocity sprayer and depositing athermoplastic polymer coating onto a substrate surface. As shown in FIG.2A, in system 20, predetermined amounts of a first thermoplastic polymerfeedstock 22 a, and a second thermoplastic polymer feedstock 22 b aredirected to a mixing vessel (not shown). The predetermined amounts ofthe first and second thermoplastic polymer feedstocks 22 a, 22 b aredelivered via first and second thermoplastic polymer powder feedstockfeedlines 21 a and 21 b, respectively, and mixed together to form athermoplastic polymer powder feedstock mixture 27. The thermoplasticpolymer powder feedstock mixture 27 is directed via feedstock mixturefeedline 28 to high-velocity sprayer 24. Feedstock mixture Feedline 28,as shown in FIG. 2A, is in communication with thermoplastic polymerpowder feedstock mixture 27 and the high-velocity sprayer 24.Predetermined amounts of the first thermoplastic powder feedstock 22 aand the second thermoplastic polymer powder feedstock 22 b can bedirected from respective feedstock supplies (not shown) by any desirablemeans, including automated means regulated by a controller (not shown)and subject to, for example, software and hardware known to control, forexample, feedstock flow rates from a supply to a sprayer, etc. Thehigh-velocity sprayer 24 can be a thermal sprayer or a cold sprayer. Asshown in FIG. 2A, the thermoplastic polymer powder feedstock mixture 27is converted by the high-velocity sprayer 24 into a thermoplasticpolymer coating 26 a deposited onto substrate 26. While thehigh-velocity sprayer 24 can be operated manually, FIG. 2A shows anoptional robotic arm 23 (equivalently referred to herein as a “robot”)that can be in communication with a controller 25. Controller 25 canfurther optionally be in communication with remote or integratedsoftware or hardware, as desired, to control robotic arm movement aswell as control flow rates and amounts of material deposited as athermoplastic polymer coating 26 a onto a substrate 26. Optionally,additional controllers (not shown) can be integrated into system 20 tocontrol one or more aspects of system 20.

FIG. 2B shows a block diagram outlining an aspect showing twothermoplastic polymer powder feedstocks and system 30 similar to system20 shown in FIG. 2A, except that, as shown in FIG. 2B, system 30comprises first and second thermoplastic polymer powder feedstockfeedlines 31 a and 31 b in communication with the high-velocity sprayer24 and the first and second thermoplastic polymer powder feedstocks 22 aand 22 b, respectively. That is, as shown in FIG. 2B, amounts of thefirst and second thermoplastic polymer powder feedstocks 22 a, 22 b arenot mixed together to form a feedstock mixture. Instead, according tothe aspect shown in FIG. 2B as system 30, a predetermined amount of thefirst thermoplastic polymer powder feedstock 22 a is directed tohigh-velocity sprayer 24 via first thermoplastic polymer powderfeedstock feedline 31 a. Similarly, a predetermined amount of the secondthermoplastic polymer powder feedstock 22 b is directed to thehigh-velocity sprayer 24 via second thermoplastic polymer powderfeedstock feedline 31 b. While the high-velocity sprayer 24 can beoperated manually, FIG. 2B shows an optional robotic arm 23(equivalently referred to herein as a “robot”) that can be incommunication with a controller 25. Controller 25 can further optionallybe in communication with remote or integrated software or hardware, asdesired, to control robotic arm movement as well as control flow ratesand amounts of material deposited as a thermoplastic polymer coating 26a onto a substrate 26. Optionally, additional controllers (not shown)can be integrated into system 30 to control one or more aspects ofsystem 30.

FIG. 3A shows a block diagram outlining an aspect showing athermoplastic polymer powder feedstock and a conductive powder feedstockand a system 40. As shown in FIG. 3A, in system 40, a thermoplasticpolymer powder feedstock 42 a, and a conductive powder feedstock 42 bare directed to a mixing vessel (not shown). The predetermined amountsof the first and second thermoplastic polymer feedstocks 42 a, 42 b aredelivered via first and second thermoplastic polymer powder feedstockfeedlines 41 a and 41 b, respectively, and mixed together to form aconductive thermoplastic polymer powder feedstock mixture 47. An amountof the conductive thermoplastic polymer powder feedstock mixture 47 isdirected via conductive thermoplastic polymer powder feedstock mixturefeedline 48 to high-velocity sprayer 44. Feedline 48 as shown in FIG. 3Ais in communication with conductive thermoplastic feedstock mixture 47and the high-velocity sprayer 44. Predetermined amounts of conductivethermoplastic polymer feedstock mixture 47 can be directed to thehigh-velocity sprayer 44 by any desirable means, including automatedmeans regulated by a controller (not shown) and subject to, for example,software and hardware known to control, for example, feedstock flowrates from a supply to a sprayer, etc. The high-velocity sprayer 44 canbe a thermal sprayer or a cold sprayer. As shown in FIG. 3A, theconductive thermoplastic polymer powder feedstock is converted by thehigh-velocity sprayer 44 into a conductive thermoplastic polymer coating46 a deposited onto substrate 46. While the high-velocity sprayer 44 canbe operated manually, FIG. 3A shows an optional robotic arm 43 (or“robot”) that can be in communication with a controller 45. Controller45 can further optionally be in communication with remote or integratedsoftware or hardware, as desired, to control movement of the robotic arm43 as well as control flow rates and amounts of deposited conductivethermoplastic polymer coating 46 a onto a substrate 46. Optionally,additional controllers (not shown) can be integrated into system 40 tocontrol one or more aspects of system 40.

FIG. 3B shows a block diagram outlining an aspect showing a conductivethermoplastic polymer powder and a system 50 similar to system 40 shownin FIG. 3A, except that as shown in FIG. 3B, system 50 comprises athermoplastic polymer powder feedstock feedline 51 a in communicationwith a thermoplastic polymer powder feedstock 42 a and a high-velocitysprayer 44. Conductive powder feedstock feedline 51 b is shown incommunication with the conductive powder feedstock 42 b and thehigh-velocity sprayer 44. That is, as shown in FIG. 3B, an amount of thethermoplastic polymer powder feedstock 42 a is not mixed with an amountof the conductive powder feedstock 42 b to form a conductivethermoplastic polymer feedstock mixture. Instead, according to an aspectshown in FIG. 3B as system 50, a predetermined amount of thethermoplastic polymer powder feedstock 42 a is directed to high-velocitysprayer 44 via thermoplastic polymer powder feedstock feedline 51 a.Similarly, a predetermined amount of the conductive powder feedstock 42b is directed to the high-velocity sprayer 24 via conductive powderfeedstock feedline 51 b. While the high-velocity sprayer 44 can beoperated manually, FIG. 3B shows an optional robotic arm 43 (or “robot”)that can be in communication with a controller 45. Controller 45 canfurther optionally be in communication with remote or integratedsoftware or hardware, as desired, to control movement of the robotic arm43 as well as control flow rates and amounts of deposited conductivethermoplastic polymer coating 46 a onto a substrate 46. Optionally,additional controllers (not shown) can be integrated into system 50 tocontrol one or more aspects of system 50.

FIG. 4A shows a block diagram outlining an aspect showing a conductivethermoplastic polymer powder feedstock and a system 60 including mixingfirst and second thermoplastic polymer powder feedstocks with aconductive powder feedstock to form a conductive thermoplastic powderfeedstock mixture, and then directing an amount of the conductivethermoplastic powder feedstock mixture to a high-velocity sprayer anddepositing a conductive thermoplastic polymer coating onto a substratesurface. As shown in FIG. 4A, in system 60, an amount of a firstthermoplastic polymer powder feedstock 62 a, an amount of a secondthermoplastic polymer powder feedstock 62 b, and an amount of aconductive powder feedstock 62 c are directed to a mixing vessel (notshown) and are mixed together to form a conductive thermoplastic polymerpowder feedstock mixture 67. A desired amount of the conductivethermoplastic polymer powder feedstock mixture 67 is directed viafeedstock mixture feedline 68 to high-velocity sprayer 64. Feedstockmixture feedline 68, as shown in FIG. 4A, is in communication withconductive thermoplastic polymer powder feedstock mixture 67 and thehigh-velocity sprayer 64. Predetermined amounts of: 1) the firstthermoplastic polymer powder feedstock 62 a; 2) the second thermoplasticpolymer powder feedstock 62 b; and 3) the conductive powder feedstock 62c are directed to the conductive thermoplastic polymer powder feedstockmixture 67 via first thermoplastic polymer powder feedstock feedline 61a, second thermoplastic polymer powder feedstock feedline 61 b andconductive polymer powder feedstock feedline 61 c, respectively, by anydesirable means. Predetermined amounts of conductive thermoplasticpolymer feedstock mixture 67 are directed to the high-velocity sprayer64 by any desirable means, including, for example, an automated meansregulated by a controller (not shown) and subject to, for example,software and hardware known to control, for example, feedstock flowrates to a sprayer, etc. The high-velocity sprayer 64 can be a thermalsprayer or a cold sprayer. As shown in FIG. 4A, the conductivethermoplastic polymer powder feedstock mixture 67 is converted by thehigh-velocity sprayer 44 into a conductive thermoplastic polymer coating66 a deposited onto substrate 46. While the high-velocity sprayer 64 canbe operated manually, FIG. 4A shows an optional robotic arm 63 (or“robot”) that can be in communication with a controller 65. Controller65 can further optionally be in communication with remote or integratedsoftware or hardware, as desired, to control movement of the robotic arm63 as well as control flow rates and amounts of deposited conductivethermoplastic polymer coating 66 a onto a substrate 66. Optionally,additional controllers (not shown) can be integrated into system 60 tocontrol one or more aspects of system 60.

FIG. 4B shows a block diagram outlining an aspect showing a conductivethermoplastic polymer powder and a system 70 similar to system 60 shownin FIG. 4A, except that as shown in FIG. 4B, system 70 comprises: 1) afirst thermoplastic polymer powder feedstock feedline 71 a incommunication with the first thermoplastic polymer powder feedstock 62 aand the high-velocity sprayer 64; 2) a second thermoplastic polymerpowder feedstock feedline 71 b in communication with the firstthermoplastic polymer powder feedstock 62 b and the high-velocitysprayer 64; and 3) a conductive powder feedstock feedline 71 c incommunication with the conductive powder feedstock 62 c and thehigh-velocity sprayer 64. That is, as shown in FIG. 4B, an amount of thefirst thermoplastic polymer powder feedstock 62 a, and an amount of thesecond thermoplastic polymer powder feedstock 62 b are not mixed with anamount of the conductive powder feedstock to form a conductivethermoplastic polymer feedstock mixture. Instead, according to system 70shown in FIG. 4B, a predetermined amount of the first thermoplasticpolymer powder feedstock 62 a is directed to high-velocity sprayer 64via first thermoplastic polymer powder feedstock feedline 71 a.Similarly, a predetermined amount of the second thermoplastic polymerpowder feedstock 62 b is directed to high-velocity sprayer 64 via secondthermoplastic polymer powder feedstock feedline 71 b. Further, apredetermined amount of the conductive powder feedstock 62 c is directedto the high-velocity sprayer 64 via conductive powder feedstock feedline71 c. While the high-velocity sprayer 64 can be operated manually, FIG.4B shows an optional robotic arm 63 (or “robot”) that can be incommunication with a controller 65. Controller 65 can further optionallybe in communication with remote or integrated software or hardware, asdesired, to control movement of a robotic arm 63 as well as control flowrates and amounts of deposited conductive thermoplastic polymer coating66 a onto a substrate 66. Optionally, additional controllers (not shown)can be integrated into system 70 to control one or more aspects ofsystem 70.

The robotic arm disclosed above is equivalently referred to herein as a“robot”, such that any feature of the robot (in addition to the “arm”)can control the relative movement of the high-velocity sprayer, and/orthe robot can control the direction of spray emitted from thehigh-velocity sprayer (e.g., the robot controls the direction and changethe direction of spray from the high-velocity sprayer while the sprayeritself remains in a substantially stationary position, etc.).

FIG. 5 is an illustration of an aircraft 80 having substrate surfacesand assemblies, sub-assemblies and components having substrate surfacesthat can be advantageously coated by the thermoplastic polymer coatingsand/or the conductive thermoplastic coatings set forth herein. It isfurther understood that, the coatings described herein can beadvantageously coated onto substrates occurring on components,assemblies and sub-assemblies incorporated in further types of mannedand unmanned aircraft, terrestrial vehicles, sub-surface and surfacemarine (e.g., water borne) vehicles, manned and unmanned satellites,etc.

FIGS. 6-8 are flowcharts outlining aspects of the present disclosure.FIG. 6 outlines a method 100 comprising directing 102 at least onethermoplastic polymer powder to a high-velocity sprayer, followed byforming 104 a thermoplastic polymer spray formulation at or near thehigh-velocity sprayer. The method outlined in FIG. 6 further comprisesdirecting 106 the thermoplastic spray formulation from the high-velocitysprayer to a substrate having a substrate surface, and forming 108 athermoplastic polymer coating on the substrate surface. The methodoutlined in FIG. 6 is understood to at least relate to the systems shownin FIGS. 1, 2A and 2B.

FIG. 7 outlines a method 100 comprising directing 102 an amount of atleast one thermoplastic polymer powder to a high-velocity sprayer,followed by directing 103 an amount of conductive powder to thehigh-velocity sprayer concurrently with thermoplastic polymer powder andforming 104 a a conductive thermoplastic polymer spray formulation at ornear the high velocity sprayer. The method further comprises directing106 a the conductive thermoplastic polymer spray formulation from thesprayer to a substrate surface, and forming 108 a a conductivethermoplastic coating on the substrate surface. The method outlined inFIG. 7 is understood to at least relate to the systems shown in FIGS.3A, 3B, 4A and 4B.

FIG. 8 outlines a method 120 comprising directing 102 a an amount of afirst thermoplastic polymer powder and an amount of a secondthermoplastic polymer powder and an amount of a conductive powder to ahigh-velocity sprayer, followed by forming 104 a a conductivethermoplastic polymer spray formulation. The method further comprisesdirecting 106 a the conductive thermoplastic polymer formulation fromthe sprayer to a substrate surface, and forming 108 a a conductivethermoplastic coating on the substrate surface. The method outlined inFIG. 8 is understood to at least relate to the systems shown in FIGS. 4Aand 4B.

Example 1

At room temperature, an amount of 95 g of PEEK powder (KetaSpire® KT820,low melt flow; KetaSpire® KT-880, high melt flow—Spire Ultra Polymers,Solvay, Brussels Belgium) having a median particle size of about 30 μmwas mixed with an amount of 5 g of conductive titanium powder(TS1374—Titanium Powder—Stanford Advanced Materials, Irvine, Calif.)having a nominal particle diameter of about 90 μm. The two powders weremixed using a Mazerustar Mixer (Medisca, LasVegas, Nev.), to form athorough conductive thermoplastic polymer powder mixture produced by thecombining of the two powders (representing 100% by weight). The mixturewas loaded as a feedstock into a reservoir of a thermal sprayer (ASCPG-550 (Alamo Supply Co., Lt., Houston, Tex.) Three formulations havinga varied amount (% by volume) of titanium in the total powder mixturewere prepared: 1) 1% titanium powder by volume; 2) 6% titanium byvolume; and 3) 9% titanium by volume.

Example 2

The thermal sprayer was set to a flow rate equal to approximately 1 to50 g/sec., and amounts of the three feedstock mixtures (conductivethermoplastic polymer powder mixtures) prepared in Example 1 were eachdirected from the reservoir into the thermal sprayer and to the heatedspray head. Each feedstock achieved a phase change, from solid to aflowing, heated sprayable liquid, and was then sprayed as a particulatespray and directed by and from the thermal sprayer to a substratesurface comprising a lap joint interface of an aluminum panel (2000,6000 and 7000 series aluminum) located proximate to a carbon fiberreinforced plastic composite panel. The substrate surface was solventcleaned (acetone wipe) and dried completely. The head of the thermalsprayer was located at a distance of about 24″ from the substratesurface. The thermal sprayer was moved manually to deposit a visuallyuniform coverage of the substrate surface. The substrate surfacetemperature was monitored with a thermostat.

Example 3

The conductive thermoplastic coatings prepared and deposited accordingto the processes described in Examples 1 and 2 were allowed to cool onthe substrate surface for not more than 5 minutes. The conductivethermoplastic coating had measured resistivity values as set forth inTable 1 for three Samples (#1, #2, and #3) having 1%, 6% and 9% byvolume of titanium in the conductive thermoplastic polymer powderformulations prepared. Adjusting the amount/concentration/ratio ofconductive titanium powder in the thermoplastic polymer (PEEK/Ti) powderfeedstock mixture resulted in a measured variance in the resistivity ofthe conductive thermoplastic polymer coating as noted in Table 1.

TABLE 1 PEEK/Titanium Powder PEEK Powder (% by total Ti Powder (% bytotal volume Resistivity volume of PEEK/Ti Mixture) of PEEK/Ti Mixture)(ohm-m) 99% 1%  1 × 10e¹⁰ 94% 6% 1 × 10e⁸ 91% 9% 1 × 10e⁷

Additional amounts of thermoplastic polymer powders were mixed withvarying amounts of conductive powders to produce feedstock mixtures thethermal spraying conducted as described above.

Further aspects of the present disclosure contemplate structural andother components for vehicles and objects including, without limitation,aircraft structures (e.g., spars, ribs, stringers, etc.), with suchcomponents finding utility at least in connection with vehicle fueltanks, fuel tank systems fuel tank assemblies, fuel tank sub-assemblies,etc. Such vehicles and objects include, without limitation, a mannedaircraft, an unmanned aircraft, a manned spacecraft, an unmannedspacecraft, a manned rotorcraft, an unmanned rotorcraft, a satellite, arocket, a manned terrestrial vehicle, an unmanned terrestrial vehicle, amanned hovercraft, an unmanned hovercraft, a manned surface water bornevehicle, an unmanned surface water borne vehicle, a manned sub-surfacewater borne vehicle, an unmanned sub-surface water borne vehicle, andcombinations thereof.

The present invention may, of course, be carried out in other ways thanthose specifically set forth herein without departing from essentialcharacteristics of the invention. The present embodiments are to beconsidered in all respects as illustrative and not restrictive, and allchanges coming within the meaning and equivalency range of the appendedclaims are intended to be embraced therein.

What is claimed is:
 1. A powdered feedstock formulation for ahigh-velocity sprayer, the formulation comprising: at least onethermoplastic polymer powder feedstock, said thermoplastic polymerpowder feedstock comprising at least one of: nylon,polyetheretherketone, polyetherketoneketone, polyamide,polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide.2. The powdered feedstock formulation of claim 1, said powderedfeedstock formulation having an average particle size ranging from about20 μm to about 300 μm.
 3. The powdered feedstock formulation of claim 1,further comprising: a thermoplastic polymer powder feedstock mixturecomprising: at least two thermoplastic polymer powder feedstocks.
 4. Thepowdered feedstock formulation of claim 3, said feedstock mixturecomprising an average particle size ranging from about 20 μm to about300 μm.
 5. The powdered feedstock formulation of claim 1, furthercomprising: at least one conductive powder feedstock combined with thethermoplastic polymer powder feedstock to form a conductive powderedfeedstock formulation; and wherein the conductive powder feedstock ispresent in the conductive powdered feedstock formulation in amountranging from about 1% to about 9% by volume of the conductive powderedfeedstock formulation.
 6. The powdered feedstock formulation of claim 5,wherein the conductive powder feedstock comprises at least one of:titanium, nickel alloy, copper, carbon black, graphene powder, andcarbon nanotubes.
 7. The powdered feedstock formulation of claim 5,wherein the high-velocity sprayer is selected from the group consistingof: a thermal sprayer and a cold sprayer.
 8. A system for delivering atunable thermoplastic polymer coating material to a substrate surface,said system comprising: an amount of a thermoplastic polymer powderfeedstock, said thermoplastic polymer powder feedstock comprising: atleast one of: nylon, polyetheretherketone, polyetherketoneketone,polyamide polyphenylsulfide, polyphenylsulfone, polysulfone, andpolyetheramide; and a high-velocity sprayer in communication with the atleast one thermoplastic polymer powder feedstock.
 9. The system of claim8, further comprising: a thermoplastic polymer powder feedstock mixturecomprising: at least a first thermoplastic polymer powder feedstock anda second thermoplastic polymer powder feedstock, said first and secondthermoplastic polymer powder feedstocks comprising an average particlesize ranging from about 20 μm to about 300 μm.
 10. The system of claim9, wherein the high-velocity sprayer is selected from the groupconsisting of: a thermal sprayer and a cold sprayer.
 11. The system ofclaim 8, wherein the system further comprises: an amount of a conductivethermoplastic powder feedstock, said conductive thermoplastic powderfeedstock comprising at least one of: titanium, nickel alloy, copper,carbon black, graphene powder, and carbon nanotubes;
 12. The system ofclaim 11, wherein the conductive powder feedstock comprises an averageparticle size ranging from about 5 μm to about 80 μm.
 13. The system ofclaim 9, wherein an amount of at least one of the first thermoplasticpolymer powder feedstock and the second thermoplastic polymer powderfeedstock are mixed with an amount of the conductive powder feedstock toform a conductive thermoplastic powder mixture.
 14. The system of claim13 further comprising: a robot in communication with the high-velocitysprayer, said robot in further communication with a controller, saidrobot configured to control movement of the high velocity sprayer.
 15. Amethod for delivering a coating to a substrate surface, said methodcomprising: directing an amount of at least one thermoplastic polymerpowder feedstock to a high-velocity sprayer to form a thermoplasticpolymer spray formulation, said thermoplastic polymer powder feedstockcomprising at least one of: nylon, polyether ether ketone, polyetherketone ketone, polyamide, polyphenylsulfide, polyphenylsulfone,polysulfone, and polyetheramide; directing the thermoplastic polymerspray formulation from the high-velocity sprayer to a substrate surface;and forming a thermoplastic polymer coating on the substrate surface.16. The method of claim 15, wherein the high-velocity sprayer isselected from the group consisting of: a thermal sprayer and a coldsprayer.
 17. The method of claim 15, further comprising: directing anamount of a first thermoplastic polymer powder feedstock to thehigh-velocity sprayer, the first thermoplastic polymer powder feedstockcomprising at least one of: nylon, polyetheretherketone,polyetherketoneketone, polyamide, polyphenylsulfide, polyphenylsulfone,polysulfone, and polyetheramide; directing an amount of a secondthermoplastic polymer powder feedstock to the high-velocity sprayer, thesecond thermoplastic polymer powder feedstock comprising at least oneof: nylon, polyetheretherketone, polyetherketoneketone, polyamide,polyphenylsulfide, polyphenylsulfone, polysulfone, and polyetheramide;and wherein the first thermoplastic polymer powder feedstock isdifferent from the second thermoplastic polymer powder feedstock. 18.The method of claim 17, further comprising: mixing the firstthermoplastic polymer powder feedstock and second thermoplastic polymerpowder feedstock to form a thermoplastic polymer powder feedstockmixture; and directing an amount of the thermoplastic polymer feedstockmixture to the high-velocity sprayer.
 19. The method of claim 15,concurrently with the step of directing an amount of at least onethermoplastic polymer powder feedstock to the high-velocity sprayerfurther comprising: directing an amount of a conductive powder feedstockto the high-velocity sprayer to form a conductive thermoplastic polymerspray formulation, said conductive powder feedstock comprising at leastone of titanium, nickel alloy, copper, carbon black, graphene powder,and carbon nanotubes; directing the conductive thermoplastic polymerspray formulation from the high-velocity sprayer to a substrate surface;and forming a conductive thermoplastic polymer coating on the substratesurface, said conductive thermoplastic polymer coating having aresistivity ranging from about 1×10e⁵ to about 1×10e⁸ ohm-m.
 20. Themethod of claim 19, further comprising; directing the conductive powderfeedstock to the high-velocity sprayer at an amount ranging from about1% to about 9% by volume of the conductive thermoplastic polymer sprayformulation.
 21. The method of claim 19, further comprising: varyingcomparative amounts of the at least one thermoplastic polymer powder andthe conductive powder to form a conductive thermoplastic polymer coatingon the substrate surface, said coating having a predeterminedresistivity ranging from about 1×10e⁵ to about 1×10e⁸ ohm-m.
 22. Themethod of claim 19, further comprising: mixing the at least onethermoplastic polymer powder feedstock and the conductive powderfeedstock to form a conductive thermoplastic polymer powder feedstockmixture; and directing the conductive thermoplastic polymer powderfeedstock mixture to the high-velocity sprayer.
 23. The method of claim17, substantially concurrently with the steps of directing the amount ofthe first thermoplastic polymer powder feedstock to the high-velocitysprayer and directing the amount of the second thermoplastic polymerpowder feedstock to the high-velocity sprayer, further comprising:directing an amount of a conductive powder feedstock to the highvelocity sprayer to form a conductive thermoplastic polymer sprayformulation, said conductive powder feedstock comprising at least oneof: titanium, nickel alloy, copper, carbon black, graphene powder, andcarbon nanotubes; directing the conductive thermoplastic polymer sprayformulation from the high-velocity sprayer to a substrate surface; andforming a conductive thermoplastic polymer coating on the substratesurface, said coating having a resistivity ranging from about 1×10e⁵ toabout 1×10e⁸ ohm-m.
 24. The method of claim 23, further comprising:varying comparative amounts of at least one of the first thermoplasticpolymer powder feedstock and the second thermoplastic polymer powderfeedstock and the conductive powder feedstock to form a conductivethermoplastic polymer coating on the substrate surface, said coatinghaving a predetermined resistivity ranging from about 1×10e⁵ to about1×10e⁸ ohm-m.
 25. The method of claim 23, further comprising: mixing thefirst thermoplastic polymer powder feedstock with the secondthermoplastic powder feedstock and the conductive powder feedstock toform a conductive thermoplastic polymer powder feedstock mixture; anddirecting the conductive thermoplastic polymer powder feedstock mixtureto the high-velocity sprayer.
 26. A substrate surface coated accordingto the method of claim
 15. 27. A substrate surface coated according tothe method of claim
 17. 28. A substrate surface coated according to themethod of claim
 19. 29. A substrate surface coated according to themethod of claim
 23. 30. An aircraft comprising the substrate surface ofclaim
 26. 31. An aircraft comprising the substrate surface of claim 27.32. An aircraft comprising the substrate surface of claim
 28. 33. Anaircraft comprising the substrate surface of claim 29.